August 2012 This month's newsletter is the first in a multi-part series on using the ANOVA method for an ANOVA

5 2.2 2.08 2.16 Gage R&R study. This method simply uses analysis of variance to analyze the results of a gage R&R study instead of the classical average and range 1 2 3 4 5 1 2 3 4 5 3.08 2.53 4.19 3.01 2.44 3.04 1.62 3.88 3.14 1.54 3.25 1.78 3.94 4.03 1.8 2.89 1.87 4.09 3.2 1.93 3.07 2.9800 0.0013 2.32 4.34 3.2 1.72 2.85 2.6947 0.0621 2.04 3.67 3.11 1.55 Sum of 0.1087 Deviations 15(Sum of 1.6304 Deviations)

Thus, SSO = 1.6304 So, you can see that the sum of squares due to the operators is based on how the operator averages deviate from the overall average. There are three operator averages. Since we calculated the overall average, we lost one degree of freedom. The degrees of freedom associated with the operators are 3 - 1 = 2, or k -1 = 2. The variability chart below shows the results by operator by part. The horizontal blue line is the average for the operator. The horizontal green line is the overall average. The difference between those two lines is the deivation. other sources of variation present in all put one of these variances. We must use the Expected Mean Square to find out what other sources of variation are present. We will use 2 to denote a variance due to a single source.

Expected Mean Squares

As stated above, the mean square column contains a variance that is related to the source of variation in the first column. To find the variance of each source of variation, we have to use the expected mean square (EMS). The expected mean square represents the variance that the mean square column is estimating. There are algorithms that allow you to generate the expected mean squares. This is beyond the scope of this newsletter. So, we will just present the expected mean squares. Lets start at the bottom with the equipment variation. This is really the within variation (also called error). It is the repeatability portion of the Gage R&R study. The expected mean square for equipment is the repeatability variance. The repeatability variance is the mean square of the equipment from the ANOVA table.

Now consider the interaction expected mean square which is given by:

Note that the EMS for the interaction tern contains the repeatability variance as well as the variance of the interaction between the operators and parts. This is what is estimated by the mean square of the interaction. The parts expected mean square is shown below. The Measurement Systems Analysis manual published by AIAG (www.aiag.org) provides the following definition: The measurement system variation for repeatability and reproducibility (or GRR) is defined as the following: GRR2=EV2 + AV2 where EV is the equipment variance and AV is the appraiser (or operator) variance. Thus:

The total variance is the sum of the components:

We can use the total variance to determine the % contribution of each source to the total variance. This is done by dividing the variance for each source by the total variance. For example, the % variation due to GRR is given by:

The results for all the sources of variation are shown in the table below. Source GRR % of Variance Total Variance 0.1109 12.14%

Equipment (Repeatability) Operators (Reproducibility) Interaction Parts Total

0.0571 0.0538 0.0000 0.8021 0.9130

6.25% 5.89% 0.00% 87.86% 100.00%

Based on this analysis, the measurement system is responsibility for 12.14% of the total variance. This may or may not be acceptable depending on the process and what your customer needs and wants. Note that this result is based on the total variance. It is very important that the parts you use in the Gage R&R study represent the range of values you will get from production. One of the major problems people have with Gage R&R studies is selecting samples that do not truly reflect the range of production. If you have to do that, you can begin to look at how the results compare to specifications. We will take a look at that next month as we compare the ANOVA method to the Average and Range method for analyzing a Gage R&R experiment. You could also use a variance calculated directly from a month's worth of production in place of the total variance in the analysis.

Summary
In this newsletter, we continued our exploration of the using ANOVA to analyze a Gage R&R experiment. We completed the ANOVA table, presented the expected mean squares and how to use those to estimate the variances of the components, and showed how to determine the %GRR as a percent of the total variance. In the next newsletter, we will compare the ANOVA method to the Average and Range method for Gage R&R.

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